Mityvac MV4535 User Manual [en, es, fr]

NOVEMBER- 2006 Form 822954 Section - MV44-1

COOLING SYSTEM AIREVAC KIT

MODEL MV4535

USER’S MANUAL

Have a technical question?

If you have questions, or require technical
service, please contact our trained service
technicians at:

1-314-679-4200 ext. 4782

Monday – Friday 7:30 am to 4:15 pm CST

Visit our website at www.mityvac.com for
new products, catalogs, and instructions for
product use.

Need service parts?

To order replacement or service parts, visit us
online at www.mityvacparts.com or call toll free
1-800-992-9898.

SPECIFICATIONS

Vacuum Air Pressure Requirements:

Min Pressure: 90 psi

(6.2 bar) (600 kPa)

Max Pressure: 120 psi

(8.3 bar) (830 kPa)

Vacuum threads for
air line connection: 1/4" NPT

Page Number - 2 Form 822954

Table of Contents

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Applications and Basics of Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Vacuum Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Refill/Airlock Elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Service Parts

Part Number Description

823032 Valve Coupler

823033 Valve Coupler Repair Kit

823035 Extension Hose

823038 Venturi Vacuum

823039 Refill Hose

823041 Vacuum Gauge

823043 Plug and Tether

MVA300 Universal Evac Adapter

823052 Custom-Molded Case

Form 822954 Page Number - 3

823033

823032

823038823035

823041823039

MVA300823043

823052

Page Number - 4 Form 822954

Vacuum Leak Test System Refill/Airlock Elimination

Vacuum Gauge

Venturi Vacuum

Extension Hose

(optional)

Extension Hose

(optional)

Valve Coupler

Universal Vacuum Adapter

Radiator

Coolant Bottle

Refill Hose

Venturi Vacuum

Extension Hose

(optional)

Valve Coupler

Universal Vacuum Adapter

Radiator

Coolant Bottle

Coupler Plug

Coupler Plug

Applications & Basics of Testing

The MV4535 Cooling System AirEvac Kit includes equipment
to perform a vacuum leak test on an automotive cooling system
that has been drained of fluid, and then to refill it quickly
without trapping air. All tests are performed with the engine
off, and when the cooling system is cool and drained of fluid.

Cooling system leaks and airlocks are a common cause of
overheating, and can be quickly diagnosed and eliminated
using the MV4535 AirEvac Kit. Although a pressure test is
most commonly used to diagnose a cooling system leak,
using vacuum is convenient because it can be performed
in conjunction with a vacuum refill. Both functions are
performed using a compressed air operated vacuum to
remove all air from a vehicle’s cooling system, and then
monitor it to determine if there are any leaks. If no leaks
are present, the vacuum is used to automatically draw in
new fluid, and fill the system without trapping air.

Precautions

This equipment is designed for servicing a variety of vehicles
in a safe, convenient manner. However, differences in cooling
systems may make it impossible to perform some of the tests
indicated in these instructions on every vehicle. The procedures
documented in this manual are to serve as guidelines for the
use of this equipment. In addition to these guidelines, always
follow the manufacturer’s recommended procedures when
servicing each unique vehicle. Do not attempt to force a test
on a cooling system for which this equipment is not designed
to perform.

Performing cooling system tests using the MV4535 is simple
and straightforward if you follow the instructions. However,
always keep in mind that you are working with a system that
may be full of cold or hot fluid that is under pressure and just
waiting to be expelled. If you are testing an engine that is hot
and/or pressurized, always stop to think before removing a cap
or disconnecting a hose or other component.

Always read carefully and understand instructions prior to using
this equipment.

Always wear eye protection when removing radiator or coolant
bottle cap, or when performing any cooling system test.

Never remove the radiator or coolant bottle cap, or attempt to
pressurize the cooling system of a vehicle that is overheated.

Always allow system to cool prior to attempting to perform any
cooling system related test procedure.

Basics of Testing

When deciding where to connect this test equipment to the
cooling system, first look for the radiator and determine if it
has a fill neck and pressure cap. This is common on about
half of US manufactured vehicles, and almost all Asian
manufactured vehicles, and would be the first choice for
connecting. If the radiator is closed and inaccessible, then
the connection will be made through a coolant bottle. Some
automotive cooling systems utilize a coolant overflow bottle
that is not part of the sealed system. Attempting to test the
cooling system through this bottle will not connect you into
the sealed system, and will simply vent the required test
vacuum to the atmosphere. This type of overflow bottle is
easily recognized because it typically utilizes a snap-on style
cap or a threaded cap that is open to atmosphere. A test
connection should be made through a radiator or coolant
bottle with a bayonet or threaded style of cap, designed to
maintain a specific pressure in the cooling system.

Universal Cooling System Adapter

The MV4535 includes a cone shaped universal adapter for
connecting the test equipment to a radiator or coolant bottle.
After removing the cooling system pressure cap from the
radiator or coolant bottle, the universal adapter will slip easily
into the neck. The adapter does not need to be forced to form
a seal. Once vacuum is applied, it will be sucked securely into
the neck, and will form an airtight seal. Once the vacuum is
relieved, the adapter can be easily withdrawn from the neck.

Form 822954 Page Number - 5

Vacuum Leak Test

For diagnosing:

Cooling system leaks

Notes

This equipment uses a venturi vacuum to perform a vacuum leak
test. The venturi requires clean, dry, high pressure air between 90
and 120 psi (5.5 - 10 bar) (550 - 1000 kpa) to create the vacuum.

Prior to testing, install a male quick-change air nipple with 1/4" NPT
male thread to the venturi.

The altitude at which the vacuum test is performed can significantly
affect the ability of the venturi to produce a vacuum. As the altitude
increases, the maximum vacuum the venturi can create will decrease.
This is normal and should not be considered a malfunction.

It is recommended that the cooling system be drained of coolant
prior to performing a vacuum leak test and automatic refill.

When connecting components using quick-connects, make sure
the sleeve snaps forward to lock the connection.

Set-up & Procedure:

1. Properly position the vehicle for service access to the radiator
or coolant bottle. Turn on the heater and set it to its highest
temperature setting.

2. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig. 1).

3. Insert the Universal Radiator Adapter into the neck of the radiator
or coolant bottle (Fig. 2).

4. Install the Valve Coupler onto the Universal Radiator Adapter
using the quick-connect. Make sure the quick-connect sleeve
snaps forward to lock the connection (Fig. 3).
Note: It may be more convenient to install an Extension Hose
between the adapter and the coupler.

5. Install the Coupler Plug into the top of the Valve Coupler and
tighten the threaded cap securely to form an airtight seal (Fig. 4).

6. Connect the Vacuum Gauge to the male quick-connect labeled
“Gauge” extending from the Valve Coupler.
Note: It may be more convenient to install an Extension Hose
between the coupler and the gauge (Fig. 5).

7. Connect the Venturi Vacuum to the male quick-connect labeled
“Pressure/Vacuum” extending from the Valve Coupler (Fig. 6).
Note: It may be more convenient to install an Extension Hose
between the coupler and the vacuum.

8. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position (Fig. 7).

9. Connect clean, dry, regulated compressed air between 90 and
120 psi (6.2 and 8.3 bar) (600 and 830 kPa) to the Venturi
Vacuum by means of the previously installed air nipple (Fig. 8).

Page Number - 6 Form 822954

Fig. 2

Fig. 4

Fig. 6

Fig. 3

Fig. 5

Fig. 7

Fig. 8

Fig. 1

Form 822954 Page Number - 7

10. Turn on the compressed air. The vacuum will make a hissing
noise as the high pressure air passes through it. If the cooling
system is not empty, it is normal that some fluid may be expelled
from the venturi exhaust.

11. Allow the vacuum to pull air from the cooling system until the
gauge indicates 24 to 26 in Hg (1.6 to 1.8 bar) (81 to 88 kPa)
or the value stops increasing (Fig. 9). This should only take about
1 to 2 minutes during which time it is normal for the radiator
hoses to collapse.

12. Once the proper vacuum is achieved, disconnect the Venturi
Vacuum from the Valve Coupler before turning off the air or
disconnecting the air hose (Fig. 10). Turning off the air or
disconnecting the air hose prior to disconnecting the venturi
from the valve coupler, will allow air to reenter the system.

13. Watch the gauge for at least 30 seconds. The vacuum reading
will remain steady if the system does not have a leak. If the
cooling system has a leak, the vacuum will drop.

14. If the cooling system has a leak, it should be located and
repaired prior to testing, and the system re-evacuated.

15. If no leak is detected and no further repairs are required,
the vacuum may be used to quickly refill the system without
trapping air. See the following section for the proper procedure
to refill the cooling system with new coolant. Otherwise, shift
the Shuttle Valve on the Valve Coupler to the “Open” position to
relieve the vacuum.

16. Disconnect components, clean and store them properly.

System Refill/Airlock Elimination

Set-up & Procedure:

Follow steps 1 through 15 of the procedures for the
Vacuum Leak Test.

1. If there are no leaks in the system, do not open the Shuttle Valve.

2. Connect the Refill Hose to the Shuttle Valve using the
quick-connect coupler (Fig. 11).

3. Place the opposite end of the Refill Hose into a supply of coolant
adequate enough to completely refill the cooling system (Fig. 12).

4. Place the coolant supply at a level even with the radiator or
coolant bottle, or higher.

5. Shift the Shuttle Valve to the “Open” position, allowing the
vacuum to pull the coolant into the system (Fig. 13).

6. If the system does not completely refill, reapply the vacuum and
repeat the refill procedure.

7. Once the refill is complete, disconnect the components, clean,
and store them properly.

8. Top off the radiator or coolant bottle if necessary, and replace
the cap properly.

Fig. 9

Fig. 10

Fig. 13

Fig. 12Fig. 11

Page Number - 8 Form 822954

Lincoln Industrial Standard Warranty

LIMITED WARRANTY

Lincoln warrants the equipment manufactured and supplied by Lincoln to be free from defects in material and workmanship for a
period of one (1) year following the date of purchase, excluding therefrom any special, extended, or limited warranty published by
Lincoln. If equipment is determined to be defective during this warranty period, it will be repaired or replaced, within Lincoln’s sole
discretion, without charge.

This warranty is conditioned upon the determination of a Lincoln authorized representative that the equipment is defective. To obtain
repair or replacement, you must ship the equipment, transportation charges prepaid, with proof of purchase to a Lincoln Authorized
Warranty and Service Center within the warranty period.

This warranty is extended to the original retail purchaser only. This warranty does not apply to equipment damaged from accident,
overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, equipment that has been altered, or equipment
repaired by anyone not authorized by Lincoln. This warranty applies only to equipment installed, operated and maintained in strict
accordance with the written specifications and recommendations provided by Lincoln or its authorized field personnel.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

In no event shall Lincoln be liable for incidental or consequential damages. Lincoln’s liability for any claim for loss or damages arising
out of the sale, resale or use of any Lincoln equipment shall in no event exceed the purchase price. Some jurisdictions do not allow
the exclusion or limitation of incidental or consequential damages, therefore the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights. You may also have other rights that vary by jurisdiction.

Customers not located in the Western Hemisphere or East Asia: Please contact Lincoln GmbH & Co. KG, Walldorf, Germany, for your
warranty rights.

Lincoln Industrial Contact Information:
To find Lincoln Industrial’s Nearest Service Center call the following numbers, or you may also use our website.
Customer Service 314-679-4200 Website: lincolnindustrial.com

Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]

Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone [phone]
Fax [phone]

Asia/Pacific:
25 Int’l Business Park
#01-65 German Centre
Singapore 609916
Phone [phone]
Fax [phone]

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